Henan Hongke Heavy Machinery Co., Ltd. has delivered an 800-ton-per-day active lime rotary kiln production line to a customer in Shaanxi Province, China. The line processes local limestone into high-reactivity quicklime for metallurgical and chemical applications.
This article covers the full project: customer background, the original problem, equipment configuration, delivery timeline, commissioning results, and customer feedback.
1. Customer Background
Location: Shaanxi Province, China
Industry: Metallurgical lime / building materials
Shaanxi is an industrial province in northwestern China with a growing metallurgical, chemical, and building materials sector. Local steel mills, calcium carbide plants, and chemical producers require a steady supply of active lime for fluxing and chemical reactions.
Our customer operates a lime production facility in Shaanxi. They supply regional industrial customers. Their existing production capacity could not meet growing demand, and lime quality from older kilns was inconsistent—particularly in reactivity and residual CO₂.
2. The Original Problem
Before approaching Henan Hongke Machinery, the customer faced several practical constraints:
| Problem | Impact |
|---|---|
| Capacity shortfall | Unable to meet contract volumes from regional customers |
| Inconsistent lime reactivity | Downstream steelmaking and chemical process efficiency affected |
| High fuel consumption | Operating cost per ton above competitive levels |
| Dust emissions | Difficulty meeting tightening environmental standards |
| Manual operation | High labor requirements, variable product quality |
| Maintenance downtime | Frequent stoppages for kiln repairs |
The customer needed a purpose-built, high-capacity lime production line—not a rebuild or upgrade of existing equipment.
3. Why the Customer Chose Henan Hongke Machinery
After evaluating several suppliers, the customer selected us for specific, practical reasons:
a) Process discussion, not just equipment quotation
Active lime production depends on the interaction of limestone properties, preheating temperature, kiln calcination profile, cooling rate, and combustion control. We discussed these parameters during technical exchange—not just dimensions and price.
b) Design matched to their limestone
Limestone from different quarries behaves differently. We reviewed the customer's limestone characteristics (particle size, CaO content, impurities) before finalizing the kiln configuration and process parameters.
c) Complete line responsibility
We supplied the full scope: vertical preheater, rotary kiln, vertical cooler, burner system, dust collection, conveying equipment, and PLC controls. The customer did not have to coordinate multiple suppliers.
d) Proven configuration for 800 TPD
The 800 TPD capacity is a well-established configuration in the industry, typically corresponding to a Φ3.6×56m rotary kiln with a matching vertical preheater and cooler.
e) Factory inspection and reference review
The customer reviewed our manufacturing facility and similar lime kiln projects before signing.
f) Long-term support commitment
The customer wanted a supplier who would remain available for process optimization and spare parts after handover.
4. Equipment Configuration
The line is built around a Φ3.6×56m rotary kiln, with a vertical preheater and vertical cooler.
| Parameter | Specification |
|---|---|
| Design capacity | 800 TPD active lime |
| Kiln diameter | 3.6 m |
| Kiln length | 56.0 m |
| Kiln slope | 3.5% |
| Rotation speed | Variable frequency drive |
| Calcination temperature | Up to 1,350°C |
| Preheater type | Vertical, multi-chamber |
| Cooler type | Vertical |
| Fuel | Pulverized coal / gas (dual-fuel capable) |
| Control | PLC-based with temperature, speed, and emission monitoring |
Scope of supply:
| System | Function |
|---|---|
| Vertical preheater | Preheats limestone using kiln exhaust gas; partial calcination before kiln entry |
| Φ3.6×56m rotary kiln | Main calcination unit; limestone decomposes to CaO + CO₂ |
| Vertical cooler | Cools lime; recovers hot air as secondary combustion air |
| Multi-channel burner | Heat input and flame control |
| Dust collection | Cyclone + bag filter; meets emission limits |
| Conveying system | Material transfer between stages |
| PLC control system | Process monitoring, data logging, interlock protection |
5. Delivery Timeline
| Stage | Status |
|---|---|
| Technical exchange and process design | Completed |
| Limestone testing and parameter definition | Completed |
| Manufacturing at Henan Hongke facility | Completed |
| Factory assembly and no-load testing | Completed |
| Shipment to Shaanxi | Completed |
| On-site installation | Completed |
| Commissioning and hot testing | Completed |
| Handover to customer | Completed |
6. Commissioning Results
| Performance Metric | Result |
|---|---|
| Production capacity | 800 TPD achieved and sustained |
| Lime reactivity | Meeting target for metallurgical applications |
| Residual CO₂ | Within specification |
| Calcination temperature | Stable across operating shifts |
| Fuel consumption | Within expected range for the process |
| Dust emissions | Within regulatory limits |
| Operational stability | Continuous operation achieved |
7. Customer Feedback
"The line has been running steadily since commissioning. Capacity meets our contract needs, and the lime quality is consistent—reactivity is where it needs to be for our customers. The engineering team was responsive during installation and commissioning. We're satisfied with the equipment and the support." — Production Manager, Shaanxi lime producer
8. What This Means for the Customer
| Benefit | Practical Value |
|---|---|
| 800 TPD capacity | Meets contract volumes for regional customers |
| Consistent lime reactivity | Stable downstream process performance |
| Lower fuel consumption | Reduced cost per ton of lime |
| Environmental compliance | Meets local emission requirements |
| Reliable operation | Fewer unplanned stoppages |
| Full-scope supplier | Single point of responsibility |
9. Building Long-Term Partnerships
Our commitment to the Shaanxi customer does not end at handover. We continue to provide:
Technical support on process optimization
Spare parts availability for critical components
Maintenance guidance and preventive maintenance planning
Support for future capacity expansion or process adjustment
About Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd. (Henan Hongke Machinery) has been designing and manufacturing industrial processing equipment since 2006. Our product portfolio includes:
Rotary Kilns – for lime, dolomite, cement, metallurgy, and mineral calcination
Rotary Dryers – for sludge, sand, gypsum, biomass, and industrial materials
Ball Mills – for ore, slag, cement, and chemical grinding
Crushers – for primary and secondary size reduction
We focus on one-stop solutions for mining and materials processing—complete systems, not just individual machines.
Let's Talk About Your Lime Project
If you are planning an active lime production line, expanding capacity, or optimizing lime quality and fuel consumption, we can discuss kiln sizing, preheater and cooler configuration, and expected performance based on your limestone data.
Contact Henan Hongke Heavy Machinery Co., Ltd.
Henan Hongke Heavy Machinery Co., Ltd.
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